Training on Powder Manufacturing

Evap & Egron Department

Nestle Milkpak Ltd. SKP 2004 M.Arshad

Evaporator

Nestle Milkpak Ltd.

SKP 2004

M.Arshad

Introduction

Nestle Milkpak Ltd.

SKP 2004

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Contents:
Milk evaporation statistics What is evaporation and why do it Characteristics of evaporation Evaporator types Falling film principle Falling Film Evaporator elements

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SKP 2004

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Global Statistics on Milk (2004)

Nestle 2.1%

World fresh milk production: 577 Mio Ton Nestle share: 12.1 Mio Ton

Nestle Others

Others 97.9%

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SKP 2004

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Statistics on Milk Processed with Evaporators (2004)

IceCream 5% Chocolate 7% Others 6%

Milk powders 50%

Fresh milk processed at Nestl: 12.1 Mio Ton Milk processed in Evaporators: 8.0 Mio Ton (66% of Nestl total milk)

Evap 7%

UHT + steril 7% White refr. 9% SCM 9%

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SKP 2004

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What is Evaporation?
Change from liquid phase to the vapour phase Vapour

For example, Boiling water

Water

Heat
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What is Condensation

Change from vapour phase to the liquid phase

Heat
Vapour

For example, Condensing steam

Condensate

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Evaporation by means of steam

Vapour Vapour at Lower temperature

Surface to exchange heat (indirect) Steam at Higher temperature

Milk Heat transfer because of temperature difference Steam

Condensate
Nestle Milkpak Ltd. SKP 2004 M.Arshad

So during evaporation:
* Solids do not evaporate ,hence * Concentration of solids in liquid phase increases

76 kg vapour

100 kg Milk, 12 % TS: 12 kg solids 88 kg water

Evaporator

24 kg Milk, 50 % TS: 12 kg solids 12 kg water

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SKP 2004

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Evaporation / Concentration Methods

Evaporator (indirect) - liquid in - liquid out Spray Dryer (direct) - liquid in - solid out Roller Dryer (indirect) - liquid in - solid out

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SKP 2004

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Why Evaporate/concentrate
Volume Reduction

For example: to reduce transport volume of Milk from source to factory.

Preservation
For example: Milk Powder: suspended bacteriological activity due to lack of water.

Convenience
For example: - Evaporated Milk.

- Instant Coffee/ Tea whitener

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SKP 2004

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Evaporator Types
The Old Vacuum Pan Recirculation Evaporators Climbing Film Evaporators Falling Film evaporators Plate Evaporators

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SKP 2004

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SPRAY DRYER

Why are Evaporators the preferred concentration equipment

(example IMP)

Fresh milk: 1000 kg

12.5%

Evaporator
time: 12-15 min

49.5%

Spray dryer
Time: 1/4-1 min

95%

Afterdryer
Time: 5-15 min

97.3%

Evaporates 747 kg of water

Energy Use = 0.07 KW/Kg H2O
Nestle Milkpak Ltd. SKP 2004

Evaporates 121 kg of water

Energy Use = 1.25 KW/Kg H2O
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Evaporates 3.1 kg of water

Energy Use = 4.2 KW/Kg H2O

Evaporator Process AT SKP

Std silo Condenser Pre-heating Thermo compressor Pasteuriser DSI Back pressure Evaporation in 1st Effect 2nd Effect 4th Effect-A&B 3rd Effect-A&B Ex-Evap Homo tank Buffer tank(if need)

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SKP 2004

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Flowsheet of SKP evap.

BRAN & LUEBBE METERING SYSTEM

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Evaporator Process
Standardized Silo
Plan Batch card Quality MSA/DPSA

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Evaporator Process
Condenser STD Milk Temp Cooling tower Preheating of milk Vapour condensation

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Condenser
Vapours are condensed by
means of Cooling Water The BIG volume 0ccupied by the Vapours

Is suddenly reduced to

To a very small volume of liquid

In
This creates a SUCTION EFFECT i.e. VACUUM

Out
Nestle Milkpak Ltd. SKP 2004 M.Arshad

Condensate
Steam Condenser Pasteurizer

Steam
PureCondensate

Condensate from Pasteurizer: --> Boiler House Condensate from 1st effect: conductivity measurement, if OK --> to Boiler House Condensate from other effects and Condenser: --> Other uses

Condensatefrom Product Vapour

Condensate from Steamrecompressed vapours

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SKP 2004

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Pre-Heaters

Pre-Heater C
Product IN

Pre-Heater 1

Pre-heat Product to ~70 C Thermal Economy

Energy has already worked upstream

Gentle heating

Low T Heating media (vapours) at the right T readily available

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SKP 2004

Evaporator Process
Balance Tank Balance tank is a feeding source of Evaporator in this we volume makeup Buffer milk & wet rework

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SKP 2004

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Thermo-Compressor
Driving Steam Sucked Vapours Compressed Vapour, mixed with Steam

Vapour Pump

H P Driving Steam recompresses and mixes with the Sucked Vapour

Simple, no moving parts Robust (not much to go wrong) Small Unit, for Large Volumes.

Fed to Heating Side of #1 Effect at higher T

To Next Effector To Condenser

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SKP 2004

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Thermocompressor Nozzle
1 M P ste am M disch 2 3 4 5 ste am

P M P suck suck

disch

1) Head 2) Steam Nozzle 3) Converging Section 4) Throat 5) Diverging Section

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SKP 2004

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Pasteuriser
Heats Product, from ~70 C to ~ 85 C Heating time is Critical
Pasteuriser

long time = Coil short time =PHE = Straight Tube

Running time > = 20h

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SKP 2004

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Nestle Milkpak Ltd.

SKP 2004

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DSI
Direct Steam Injection

Short Time Heat Treatment Heat Product from 85 C to say 108C Followed by Holding Tube -Holding time - 5 to 10 Sec

-Variable holding time as needed

-Watering effect ~ 4% for 20C temperature rise

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SKP 2004

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Back Pressure
Why Back Pressure?

Product at high T >100 C Uniform flow To avoid boiling Ensures:

Correct T is reached Correct holding time Premature Flashing

Prevents:

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Evaporator Process
Evaporation in 1st Effect

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Product Inlet Nozzle at ist effect

Product FeedUnder Pressure d l The Back pressure will depend on "l" and "d", calculated for a certain flowrate

Flow through S.S. Nozzle And Diverter

Calandria Top Cover

FlashVapour
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Evaporator Process
Evaporation in 2nd Effect

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Evaporator Process
Evaporation in 4th Effect-A&B

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Evaporator Process
Evaporation in 3rd Effect-A&B

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Evaporator Process
Ex-Evap Ex Evap is a point milk can divert in three direction Balance tank for circulation Buffer tank in case of problem on Egron Homo tank for Egron feeding

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SKP 2004

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Evaporator Process
Homo tank Homo tank feeding source of Egron Its level always on minimum position 20 to 40 % for better quality

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SKP 2004

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Evaporator Process
Buffer tank Capacity of Buffer Tank 3800 Lt Milk taken in Buffer Tank when the problem on Egron If the dietetic product then milk transfer in STD If the nondietetic product then milk reused in the balance tank Temperature of milk should be 4 to 8

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SKP 2004

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Falling Film Evaporator

Product In steam vapour
Is mainly a heat exchanger with vertical tubes.

The Product flows from top to bottom inside the tubes --> FALLING
The Product is fed to form a thin FILM inside the tube

Product Out condensate

Nestle Milkpak Ltd. SKP 2004

FALLING FILM EVAPORATOR

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The film:
Boiling Tube

Vapours

Product
Inside the Boiling Tube

Steam Vapours

- Thin Film of Product - Evaporated Vapours

Condensate
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Outside the Boiling Tube - Steam / Vapours

- Condensed Steam

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SKP 2004

The film:

Calandria Top
Product Strainer

Product from back pressure device

Distribution Traywith Vapour Tubes and Calibrated orifices Tube-End-Plate Flooded Boiling Tube With Product film inside
Nestle Milkpak Ltd. SKP 2004 M.Arshad

With Flash Vapours

Steam outside B. Tube

The film:
Product
Boiling Tube Center Line

Product overflows into tubes from all sides

Boiling Tube

End Plate of Tubes

Boiling Tube
Vapours help keeping film against the tube
Nestle Milkpak Ltd. SKP 2004 M.Arshad

Vapours

Product

Boiling Tube

Stea m Vapours

Stea m Vapours
Condensate

Condensed Water with Increasing FILM thickness

Condensate

Vapours

Critical Liquid Product on all Heat Exchange Area Equal Distribution among tubes Even Coverage on all inside of tube ==> Liquid Load.
Nestle Milkpak Ltd. SKP 2004 M.Arshad

Product FILM Thickness Decreasing as Water evaporates

Liquid load
Product mass flow M product = Meter pipe circumfere nce n d
n = number of boiling tubes d = diameter of boiling tube in kg/(m.h) In practice if < certain value: Film unstable Film may be torn off Film will dry out Film will burn Fouling Ultimately completely block tubes.
Nestle Milkpak Ltd. SKP 2004 M.Arshad

How can we increase the Liquid Load?

By Recirculation
10 T/h Recirculation

By Splitting the Effect

10 T/h

Vapours Vapours 4 T/h

Vapours

Mvap A + Mvap B

B 6 T/h over 40 tubes

A 7.3 T/h over 60 tubes

6 T/h
6 T/h
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SKP 2004

Falling film evaporator Elements

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SKP 2004

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Falling Film Evaporator

DSI Steam Back Pressure Control Distribution Calandria

Steam
THC

Pre-heater C
Product IN

Pasteuriser
Steam

Pre-heater 1

Condenser

Separator

Condensate

Condensate

Cooling Water IN Product OUT Cooling Water OUT

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SKP 2004

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Elements of a Falling Film Evaporator

Going with the Product Flow...

Product IN

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Elements of a Falling Film Evaporator

Pre-heater C, PHC
Product IN

Pre-heater 1, PH1

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SKP 2004

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Elements of a Falling Film Evaporator

Pre-heater C
Product IN

Pasteuriser
Steam Condensate.

Pre-heater 1

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SKP 2004

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Elements of a Falling Film Evaporator

DSI
Steam.
Pre-heater C
Product IN

Holding element

Pasteuriser Steam

Pre-heater 1

Condensate

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SKP 2004

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Elements of a Falling Film Evaporator

Holding element
DSI Steam
Distribution Back Pressure Control

Pre-heater C
Calandria

Product IN

Pasteuriser Steam

Pre-heater 1

Separator
Condensate
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Product OUT
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Elements of a Falling Film Evaporator

Steam

On the Vapour Side....

Sucked vapours
Back Pressure Control Distribution Pre-heater C Calandria
Product IN

DSI Steam Thermo-compressor or THC

The Vapours are recompressed by the THC

Steam

Pre-heater 1

Separator

Condensate Product OUT

Nestle Milkpak Ltd. SKP 2004 M.Arshad

Elements of a Falling Film Evaporator

DSI Steam THC

Steam
Back Pressure Control Distribution Calandria
Product IN

Condenses Vapours
Pre-heater C

Pasteuriser Steam

Pre-heater 1

Condenser

Separator

Condensate
Cooling Water IN

Condensate
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Cooling Water OUT

Elements of a Falling Film Evaporator

DSI Steam THC

Steam

Water side of Back Pressure Control Condenser can be De-aerated Distribution Pre-heater C Calandria
Product IN

Pasteuriser Steam

Pre-heater 1

Condenser

Other elements are Deaerated by Diaphragms

Nestle Milkpak Ltd. SKP 2004

Non-Condensables are evacuated by Separator The Vacuum Cooling System Water Product OUT
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When to Pasteurise ?

Upstream of Evaporation Pasteurisation prevents:

Subsequent bacteriological Development

Pasteurisation provides:
Heat stability to milk and thereby reduced fouling in evaporator

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SKP 2004

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P0 , T 0
say: 2 bar, 100C

FLASH
When a liquid at higher P, T Enters into a medium with lower P, T it will evaporate some liquid to cool it to the new mediums T. the vapour so produced is called

Expansion Vessel at P1, T1 say :286 mbar, 68C

Flash

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Separator
Droplets of liquid must be separated from the Vapours: Cyclone

Vapour Discharge Vapour Duct

Vapour Discharge at Top Droplets, Liquid, Downwards

Critical: Vapour Velocity

Calandria
Product to Discharge Pump
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depends on: -Mass flow -Vapour Density.

Separator
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De-Aeration
Condenser

Steam

System contains Air (gases) that must be removed to have good heat exchange
Air (gases) evacuated via Calibrated diaphragms to: - next Effect - or to the Condenser.

De-Aeration
Orifice

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SKP 2004

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Vacuum system
VACUUM is made by the Condenser, but
Condenser

VACUUM is MAINTAINED by evacuating the non condensables by means of:

VACUUM SYSTEM - Vacuum Pump - Ejectors

Cooling Water

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Vapour Ducts

Carry the vapours to the next effect, to the Condenser or to THC Critical: Vapour velocity
Pressure Drop

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How is an Evaporator Controlled ?

More Steam = More Evaporation
Provided Equipment operate within allowable:

Design thermal Load THC operating range Vapour velocities, calandria and separator Liquid loads Temperature profile

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Control, Action & Reaction

CONTROL ACTION Steam kg/h Water kg/h REACTION Process C Product out TS %

Product at Inlet
TS % C kg/h

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SKP 2004

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Advantages
Small liquid content and high flow velocities:

Short residence time, gentle evaporation Small amount of cleaning agent needed Good controllability and automation High final concentrations possible
Can operate at low delta T, since operation independent of thermal force like in Circulation evaporators Possible to use 15 m or longer tubes

Allows application of Falling Film principle for virtually all capacities

Uniform thermal treatment of product

Nestle Milkpak Ltd.

SKP 2004

M.Arshad

Thank you
Nestle Milkpak Ltd. SKP 2004 M.Arshad